Manual Transmission Overhaul – ’92-95

by NinjaX on June 21, 2010

Manual transmission overhaul applies to Honda Civic 1992-1995.

TRANSMISSION DISASSEMBLY
Place clutch housing on supports high enough to keep mainshaft from hitting workbench. If it is necessary to heat transmission case for component removal, DO NOT exceed 212°F (100°C).

Measure clearance between 2nd and 3rd gears. See figure. If clearance is greater than service limit, measure thickness of 3rd gear. If thickness is within specifications, replace 3rd/4th synchro hub. If thickness is not within specifications, replace 3rd gear.

Measure clearance between 4th gear and spacer collar. If clearance is greater than service limit, measure distance “A” on spacer collar. If distance “A” is greater than specifications, replace spacer collar. If distance “A” is within specifications, measure thickness of 4th gear. Replace 4th gear if thickness exceeds specification. If thickness is within specifications, replace 3rd/4th synchro hub.

Remove synchro hubs using press and steel blocks. Use of jaw-type puller can damage gear teeth.

Disassembly
Use puller to remove bearing. Support 4th gear on steel blocks, and press mainshaft out of 5th synchro hub. Support 3rd gear on steel blocks, and press mainshaft out of 3rd/4th synchro hub. Remove remaining components.

Inspection

Inspect all parts for damage and wear. Replace if necessary. Clean all parts in solvent, then dry and lubricate all parts. Ensure oil passages are free of contamination.

Measure mainshaft at points “D”, “E”, “F” and “G”. See figure. Support mainshaft on “V” blocks. Using dial indicator, measure runout while rotating mainshaft 2 complete revolutions. Replace mainshaft if runout or any part of shaft is not within service limit.

Calculate shim thickness as follows: “B” + “C” – .95 = shim thickness. The number .93 is mid point of flex range of clutch housing bearing spring washer. DO NOT use more than 2 shims. Shims are available in 0.3-mm increments. Shim thickness ranges from .0236″ (.60 mm) to .0709 (1.80 mm). On 1.5L engines, shim diameter is 2.55″ (65 mm). On 1.6L engines, shim diameter is 2.75″ (70 mm). Shim thickness is the same for both shim sizes. Part numbers for 1.5L engines are 23931-PL3-A10 through 23971-PL3-A10. Part numbers for 1.6L engines are 23931-PL3-B00 through 23971-PL3-B00.

Clearance should be .004-.007″ (.11-.18 mm). If reading is not correct, recheck shim thickness.

COUNTERSHAFT MEASUREMENTS

Measure clearance between 1st gear and countershaft. See figure. If clearance exceeds service limit, measure thickness of 1st gear. If thickness is less than service limit, replace 1st gear. If thickness is within specification, replace 1st/2nd synchro hub

Measure clearance between 2nd gear and 3rd gear. If clearance exceeds service limit, measure distance “A” on spacer collar. If distance “A” is less than service limit, replace collar. If distance “A” is within specification, measure thickness of 2nd gear. Replace 2nd gear if thickness is less than service limit. If thickness is within specification, replace spacer collar.

COUNTERSHAFT SPECIFICATIONS

1st Gear-To-Countershaft Clearance

Standard .001-.004″ (.03-.10 mm)

Service Limit .009″ (.22 mm)

2nd Gear-To-3rd Gear Clearance

Standard .001-.004″ (.03-.11 mm)

Service Limit .009″ (.23 mm)

1st Gear Thickness

Standard 1.197-1.198″ (30.41-30.44 mm)

Service Limit 1.195″ (30.36mm)

2nd Gear Thickness

Standard 1.257-1.259″ (31.92-31.97 mm)

Service Limit 1.254″ (31.85 mm)

Spacer Collar Height “A”

Standard 1.261-1.262 (32.03-32.06 mm)

Service Limit 1.260″ (32.01 mm)

Remove synchro hubs using press and steel blocks. Use of jaw-type puller can damage gear teeth.

Disassembly
Using chisel and hammer, raise lock nut tab away from groove in countershaft. Remove lock nut and spring washer. Use bearing puller to remove top ball bearing. Use bearing splitter or appropriate blocks to support 4th gear. Press countershaft out of 4th gear and 5th gear. Support 1st gear, and press countershaft out of 3rd gear. Remove remaining parts.

Inspection

Inspect all parts for damage and wear. Replace if necessary. Clean all parts in solvent, then dry and lubricate all parts. Using press, install 3rd, 4th and 5th gears before lubricating.

Measure the countershaft at points “D”, “E” and “F”. See figure. Support countershaft on “V” blocks. Using dial indicator, measure runout while Rotating countershaft 2 complete revolutions. Replace countershaft if runout or any part of countershaft is not within service limit.

Measure clearance between each shift fork and its matching synchro sleeve. Clearance should be .010-.018″ (.25-.45 mm). Service limit is .031″ (.80 mm). If clearance exceeds service limit, measure thickness of shift fork fingers. Finger thickness should be .252-.256″ (6.40-6.50 mm). If either measurement is not within specifications, replace sleeve and shift fork.

Inspect gear teeth for wear, galling, roughness and cracks. Ensure ring and gear turn freely. If replacement is necessary, replace ring and gear as a unit.

Measure ring-to-gear clearance all the way around. See figure. Ensure ring is held evenly against gear while measuring. Ring- to-gear clearance should be .033-.043″ (.85-1.10 mm). Service limit is .016″ (.40 mm). If clearance exceeds limit, replace ring and gear as a unit.

Reassembly
Each synchro sleeve has 3 sets of longer teeth (120 degrees apart) that must be matched with 3 sets of deeper grooves when hub is assembled. See figure.